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I. PURPOSE
The purpose of a Run @ Rate is to verify:
A. the supplier's actual manufacturing process is capable of producing components that meet GM's on-going
quality requirements, as stated in the Production Part Approval Process (PPAP), at quoted tooling capacity for
a specified period of time; and
B. the supplier's actual manufacturing process conforms to the manufacturing and quality plan documented by the
supplier in PPAP, GP-12 and other required documentation.
During a Run @ Rate, all production tooling is to be in place and running at full capacity, utilizing all regular
production, direct and indirect, personnel and support systems.
II. SCOPE
All new parts require a Run @ Rate, unless exempted by the supplier quality engineer and approved by the
Supplier Quality and Purchasing Directors of the procuring division.
During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and
results; part quality requirements and results; sub-supplier requirements and Run @ Rate results; and
packaging.
A. DOCUMENTATION:At the time of the Run @ Rate, the following support documentation should be
available for review:
1. PPAP package including:
a) Process flow diagram
b) Process control plan, with reaction plan
c) DFMEA/PFMEA
d) Master part(s)
2. GP-12 (Pre-launch) control plan
3. Tool capacity information
4. Operator/inspection instructions
5. Prototype/pilot concerns (PR/R's)
6. Sub-contractor control/capacity data
7. Sub-contractor material schedules and transportation
8. Packaging/labeling plan
9. Acceleration plan.
Note: All documentation must be complete and correct.
B. MANUFACTURING PROCESS – ACTUAL TO PLAN
1. The product is being manufactured at the production site using the production tooling,
gaging, process, materials, operators, environment, and process settings.
2. The actual process flow agrees with the process flow diagram, as documented in PPAP.
3. Operator instructions/visual aids are available and adhered to at each work station.
4. All in-process documents, such as process control charts, are in place at the time of the Run
@ Rate. The documentation is utilized to drive a defined reaction plan and corrective action process.
5. Production boundary samples, when required, are available at required work stations.
6. Maintenance plans are in place; repair and maintenance parts are available; and there is
planned downtime for preventative maintenance.
Note: All of the preceding requirements must be met to pass the Run @ Rate.
C. MANUFACTURING CAPACITY RESULTS
The following will be verified while the process is running.
1. Net output from each operation can support quoted capacity.
2. During the Run @ Rate, the tooling must meet the quoted up time requirements (net vs.
gross quoted output). Any unexpected downtime must be documented and corrective action taken.
3. All line changeovers, if any, can be performed within the quoted tooling capacity
requirements.
4. The net through-put of good pieces (scrap taken out, any allowable rework) meet daily
quoted capacity.
5. The acceleration plan is sufficient to meet requirements.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
D. PART QUALITY PLAN TO ACTUAL
1. All production checking fixtures must be complete, with acceptable measurement system
studies (i.e., gage R and R) performed, and operator instructions/visual aids available.
2. All in process gaging and controls must be complete, functional and in place.
3. The process control plan (normal and GP-12) must agree with the actual process. Production
part checks and statistical monitoring must take place as outlined on the process control plan.
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4. Potential failure modes, as identified in the PFMEA, are addressed through error-proofing or
the control plan.
5. The process control plan reaction plan as well as the supplier's corrective action process to
ensure containment and correction should be available for review.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
E. PART QUALITY RESULTS
1. All parts produced off production tooling during the Run @ Rate meet GM's requirements
for ongoing quality, as stated in PPAP.
2. The manufacturing process is in control.
3. The manufacturing process demonstrates the required capability.
4. The process control plan is sufficient to effectively meet the design record requirements
(i.e., control points, frequency of checks, etc.).
5. Nonconformances
Note: The total number of parts produced, the pieces rejected and the pieces reworked need to be
documented on the summary sheet.
a) The non-conformances yielded by the process were identified by the normal PPAP control
plan. If identified by the GP-12 Process Control Plan or an activity outside documented plans,
corrective action is required.
b) The PFMEA identified the potential failure modes. If not, the PFMEA needs to be updated
and corrective action put in place.
c) All rework and repairs effectively correct the nonconformance(s).
d) All prototype and pilot concerns, if any, have been corrected and validated.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
F. SUBCONTRACTOR REQUIREMENTS
1. Subcontractor(s)' abilities to meet the customer's quality and capacity requirements must be
confirmed by the supplier prior to the Run @ Rate being conducted at the supplier's facility.
Verification of the subcontractor(s)' manufacturing processes should be accomplished through a Run
@ Rate or similar process conducted by the supplier.
2. Controls must be in place to isolate incoming material until it has been approved.
Note: The preceding requirements must be met to pass the Run @ Rate.
G. PACKAGING AND HANDLING
1. In process and final shipment packaging will be reviewed for preservation of part quality
and ease of use by supplier's operators loading and unloading parts. (Refer to GM 1738 for
requirements.)
2. The supplier's method for in process and final shipping packaging and handling must
effectively eliminate the potential for process errors or mixed stock.
VII. APPROVAL
Upon completion of the Run @ Rate, the worksheets must be reviewed for completeness and a decision made
whether or not to approve the review. The Run @ Rate can have one of three results: pass; open or fail.
A. Pass
1. Definition
Pass indicates that all Run @ Rate requirements were met. The supplier demonstrated the capability
to produce parts that meet GM's on-going quality requirements at quoted capacity (net output). All
key product characteristics were monitored and meet Cpk/Ppk requirements. GP-12 requirements
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were met. The supplier's actual manufacturing process agreed with the manufacturing and quality
plan, as documented by the supplier in PPAP, GP-12 and other required documentation. Quality
systems were documented and practiced.
B. Open
1. Definition Open indicates that some minor non-conformances to the requirements were
found that need to be corrected. Examples of this are net output meets volume requirements but not
quoted capacity; quality systems have minor deficiencies (i.e., preventative maintenance system
lacking, lack of error proofing, incomplete or inadequate operator instructions/visual aids, operator
training not complete, minor deficiencies in meeting customer's ongoing quality requirements).
2. Corrective Action Required A documented Action Plan to correct the non-conformances is
required. At a minimum, it must include the name of the individual at the Supplier who is responsible
for implementing the Corrective Action and the timing and validation of the Corrective Action Plan.
This plan is due to the GM Run @ Rate Supplier Quality Engineer for approval, within two (2)
business days of the completion of the Run @ Rate.
3. Verification of Corrective Action GM verification of successful completion of the corrective
action plan can be accomplished in several different ways, for example, through correspondence, a
part review or a plant visit. Generally an additional Run @ Rate is not required. Once the Corrective
Action plan is successfully completed, the Supplier Quality Engineer will change the Run @ Rate
result from open to pass.
C. Fail
1. Definition Fail indicates a serious non-conformance exists that requires significant action by
the supplier to correct, such as quality systems are not in place and serious non-conformances exist;
Ppk values (Cpk values) do not meet requirements for KPC’s; or supplier fails to meet Volume
Requirements. An additional Run @ Rate will be required.
2. Corrective Action Required A documented Action Plan to correct the non-conformances is
required. At a minimum, it must include the name of the individual at the Supplier who is responsible
for implementing the Corrective Action and the timing and validation of the Corrective Action Plan.
This plan is due to the GM Run @ Rate Supplier Quality Engineer for approval, within two (2)
business days of the completion of the Run @ Rate.
3. Verification of Corrective Action. Once the Corrective Action plan is completed, the
Supplier Quality Engineer will schedule the new Run @ Rate to verify the successful implementation
of the corrective action plan.
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Note: If the supplier monitored Run @ Rate results in a fail, another Run @ Rate must be scheduled with a customer
representative present
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Customer______________________________________ Buyer_______________________________
Phone #
Planned Usage: Daily____________ Weekly__________ SQE________________________________
Phone #
RESULTS
Actual Hours______________ From _________ To__________ ACTUAL (net good parts)
Actual Shifts______________ Date ____________ ___________________/Hour
Actual Downtime Hours _____________(planned & unplanned) ___________________/Shift
Explain: _______________________________________ ___________________/Day
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Total Produced _____________________ - Total Rejected ______________________ = Net _____________
Comments/Open Issues:
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COMMENTS:
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1965
GENERAL MOTORS SUPPLIER DEVELOPMENT
Page 8 of 11 GENERAL PROCEDURE
During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and results; part
quality requirements and results; sub-supplier requirements and Run @ Rate results and packaging.
A. Documentation
At the time of the Run @ Rate, the following support documentation should be available for review:
Available Y/N
1.
PPAP package including: 1.______
a) process flow diagram a._____
b) process control plan, with reaction plan b._____
c) DFMEA/PFMEA c._____
d) Master part(s) d._____
2. GP-12 (Pre-launch Control) plan 2.______
3. Tool capacity information 3.______
4. Operator/inspection instructions 4.______
5. Prototype/pilot concerns (PR/R's) 5.______
6. Sub-contractor control/capacity data 6.______
7. Sub-contractor material schedules and transportation 7.______
8. Packaging/labeling plan 8.______
9. Acceleration plan 9.______
Note: All documentation must be complete and correct.
B. MANUFACTURING PROCESS -- ACTUAL TO PLAN
1. Is the product being manufactured at the production site using the production tooling, gaging, process,
materials, operators, environment, and process settings? Yes _____No _____
Comments:_______________________________________________________________________________
________________________________________________________________________________________
2. Does the actual process flow agree with the process flow diagram, as documented in PPAP? (Review the
facility plan and layout. Walk the process with the flow diagram.) Yes _____No _____
Comments:_______________________________________________________________________________
________________________________________________________________________________________
3. Are operator instructions/visual controls available and adhered to at each work station?
Yes _____ No _____ Comments:_____________________________________________________________
________________________________________________________________________________________
4. Is all in-process documentation, such as process control charts, in place at the time of the Run @ Rate? Is the
documentation utilized to drive a defined reaction plan and corrective action process?
Yes_____No_____Comments:_______________________________________________________________
________________________________________________________________________________________
5. When required, are production boundary samples available at required work stations? Are the boundary
samples approved by GM? Yes _____No _____ Comments:_______________________________________
________________________________________________________________________________________
6. Are maintenance plans in place? Are repair and maintenance parts available? Is there planned downtime for
preventative maintenance? Yes _____No _____ Comments: _______________________________________
________________________________________________________________________________________
Note: All of the preceding requirements must be met to pass the Run @ Rate.
Comments:__________________________________________________________________________________
2. During the Run @ Rate, did the tooling meet the quoted up time requirements (net vs. gross quoted output)?
Make note of any unexpected downtime and corrective action plans required. Yes _____ No _____
Comments: ______________________________________________________________________________
________________________________________________________________________________________
3. Can all line changeovers, if any, be performed within the quoted tooling capacity requirements?
Yes _____ No _____ Comments: ____________________________________________________________
________________________________________________________________________________________
4. Does the net through-put of good pieces (scrap taken out, any allowable rework) meet daily quoted capacity?
Yes _____ No _____ Comments: ____________________________________________________________
________________________________________________________________________________________
5. Is the acceleration plan sufficient to meet requirements? Yes _____ No _____
Comments: ______________________________________________________________________________
________________________________________________________________________________________
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
________________________________________________________________________________________
2. Are all in process gaging and controls complete, functional and in place? Yes _____ No _____
Comments: ______________________________________________________________________________
________________________________________________________________________________________
3. Do the process control plans (normal and GP-12) agree with the actual process? Do production part checks
and statistical monitoring take place as outlined on the process control plan?
Yes _____ No _____ Comments: ____________________________________________________________
________________________________________________________________________________________
1960
GENERAL
Page 10 of MOTORS
11 SUPPLIER DEVELOPMENT GENERAL PROCEDURE
5. Do the process control plan reaction plan and the supplier's corrective actions ensure effective
containment and correction? Yes _____No _____ Comments:__________________________
____________________________________________________________________________
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
3. Does the manufacturing process demonstrate the required capability? Yes _____No _____
Comments: _____________________________________________________________________
_______________________________________________________________________________
4. Is the process control plan sufficient to effectively meet the design record requirements, i.e., control
points, frequency of checks, etc.? Yes _____No _____ Comments: _________________________
_______________________________________________________________________________
5. Nonconformances
a) Were the non-conformances yielded by the process identified by the normal PPAP control plan?
Yes _____ No _____ If identified by the GP-12 Process Control Plan or an activity outside
documented plans, corrective action is required.
b) Did the PFMEA identify the potential failure modes? Yes _____ No _____ If not, the PFMEA
needs to be updated and corrective action put in place.
c) Do all the observed rework and repairs effectively correct the nonconformance(s)?
Yes _____ No _____
d) Are there any open concerns from prototype or pilot (PR/R)? Yes _____ No _____
Comments: _________________________________________________________________
___________________________________________________________________________
Note: All of the preceding requirements must be met to pass the Run @ Rate.
F. SUBCONTRACTOR REQUIREMENTS
1. Were subcontractors' abilities to meet the customer's quality and capacity requirements confirmed
by the supplier prior to the Run @ Rate being conducted at the supplier's facility? Was verification
of the subcontractors' manufacturing processes accomplished through a Run @ Rate or similar
process conducted by the supplier?
Yes _____No _____ Comments: ____________________________________________________
_______________________________________________________________________________
2. Are Controls in place to isolate incoming material until it has been approved?
Yes _____No _____ Comments: ____________________________________________________
_______________________________________________________________________________
Note: The two preceding requirements must be met to pass the Run @ Rate.
_______________________________________________________________________________
2. Does the supplier's method for in process and final shipping packaging and handling effectively
eliminate the potential for process errors or mixed stock? Yes _____No _____
Comments: _____________________________________________________________________
_______________________________________________________________________________
COMMENTS:
_______________________________________________________________________________
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1960